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Home >> Lexus >> 2021 >> RC F Fuji Speedway Edition >> Repair and Diagnosis >> Engine Mechanical >> Fuel System >> Fuel System - Service Information >> FUEL INJECTOR (for Direct Injection) >> Installation [09/2014 - ] >> Procedure

Installation [09/2014 - ]: Procedure

  1. INSTALL FUEL INJECTOR SEAL 
    1. Apply engine conditioner to the area shown in the illustration. Using a piece of cloth, clean carbon deposits from the fuel injector assembly and its grooves.
      GTY505660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Area to be Cleaned
      NOTE:
      • Do not clean the tip of the fuel injector assembly.
      • Do not use a wire brush to clean the fuel injector assembly.
      • If a fuel injector assembly is dropped or the tip of a fuel injector assembly is struck, replace it with a new one.
    2. Apply engine oil to the fuel injector assembly contact surface of SST (guide), then attach SST (guide) to the fuel injector assembly with the chamfer facing the tip of the fuel injector assembly as shown in the illustration.
      GTY515764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Guide)
      *b Chamfer
      • SST: 09260-39021 
        1. 09261-03020
    3. Install a new fuel injector seal to SST (holder).
      GTY510414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Injector Seal
      *a SST (Holder)
      *b Correct
      *c Incorrect
      • SST: 09260-39021 
        1. 09261-03011
      NOTE:

      Be careful not to install the fuel injector seal to SST (holder) at an angle. Doing so will stretch the fuel injector seal.

    4. Install SST (holder) with the fuel injector seal to the tip of the fuel injector assembly. Slide the fuel injector seal downward into the fuel injector assembly groove with your fingers as shown in the illustration.
      GTY519166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Holder)
      *b SST (Guide)
      • SST: 09260-39021 
        1. 09261-03011
        2. 09261-03020

      HINT: 

      Check that the fuel injector seal is seated in the fuel injector assembly groove as shown in the illustration.

    5. Slowly slide SST (guide) toward the tip of the fuel injector assembly. When the fuel injector assembly contact surface of SST (guide) aligns with the fuel injector seal as shown in the illustration, hold the position for 5 seconds or more to fully seat the fuel injector seal into the fuel injector assembly groove.
      • SST: 09260-39021 
        1. 09261-03020
      GTY499008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Guide)
      NOTE:

      Be sure that the fuel injector seal is not pinched between SST (guide) and the edge of the fuel injector assembly groove. Replace the fuel injector seal if it becomes damaged.

      HINT: 

      • Set SST (guide) so that its bottom surface is flush with the fuel injector seal.
      • If it is difficult to slide SST (guide) upward, slowly wiggle it from side to side while sliding it up the fuel injector assembly little by little.
    6. After installing the fuel injector seals, check that they are not scratched, deformed or protruding from the fuel injector assembly groove.
      GTY516118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Normal
      *b Protruding
      *c Deformed
      *d Correct
      *e Incorrect
      NOTE:

      If a fuel injector seal is scratched, deformed or protruding from the groove, replace it with a new one.

  2. INSTALL FUEL INJECTOR ASSEMBLY 

    HINT: 

    Perform "Inspection After Repair" after replacing a fuel injector assembly.

    Refer to INITIALIZATION [09/2014 - ]

    1. Install a new injector vibration insulator and a new C-ring to the fuel injector assembly.
      GTY506902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Injector Assembly
      *2 C-ring
      *3 Injector Vibration Insulator
      *a Taper
      NOTE:
      • Install the taper of the injector vibration insulator by aligning it with the taper of the fuel injector assembly.
      • Check that the C-ring is securely seated in the groove of the fuel injector assembly.
    2. Install a new O-ring and new No. 1 fuel injector back-up ring to the fuel injector assembly as shown in the illustration.
      GTY507233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Fuel Injector Back-up Ring *2 O-ring
      *a No. 1 Fuel Injector Back-up Ring Opening *b Overlapped
      *c Stretched *d Correct
      *e Incorrect - -
      NOTE:
      • Check that there is no foreign matter or damage on the O-ring groove of the fuel injector assembly.
      • Make sure that the No. 1 fuel injector back-up ring is installed in the correct orientation.
      • Make sure that the No. 1 fuel injector back-up ring and O-ring are installed in the correct order.
      • Check that the opening of the No. 1 fuel injector back-up ring is not overlapped or stretched as shown in the illustration.
      • After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
    3. With the notch of a new No. 3 fuel injector back-up ring facing downward, install the fuel injector assembly to the No. 3 fuel injector back-up ring as shown in the illustration.
      GTY514487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Injector Assembly
      *2 No. 3 Fuel Injector Back-up Ring
      *a Notch
      NOTE:
      • Make sure that the No. 3 fuel injector back-up ring is installed in the correct orientation.
      • After installing the No. 3 fuel injector back-up ring, make sure there is no damage or foreign matter.
    4. Install the nozzle holder clamp to each fuel injector assembly.
    5. Align the protrusion of the nozzle holder clamp with the positioning hole of the fuel delivery pipe LH, fuel delivery pipe RH and insert the fuel injector assembly.
      GTY501721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Positioning Hole
      No Gap
      NOTE:
      • Make sure that there is no foreign matter or damage inside the fuel injector assembly installation holes (fuel delivery pipe LH and fuel delivery pipe RH).
      • Do not allow gasoline to get on the O-rings or inside the installation holes.
      • If it is difficult to insert the fuel injector assembly, apply new engine oil to the chamfer of the fuel injector assembly installation hole of the fuel delivery pipe LH and fuel delivery pipe RH. Be careful not to allow the fuel injector assembly to fall out of the fuel delivery pipe LH or fuel delivery pipe RH.
      • Do not tilt the fuel injector assembly when inserting it into the fuel delivery pipe LH and fuel delivery pipe RH.
      • Check that there is no gap between the fuel delivery pipe LH, fuel delivery pipe RH and the nozzle holder clamp.
      • Make sure the 4 fuel injector assemblies have the same flow classification number 1, 2 or 3 (the number to the left of the QR code) on each bank (8 fuel injector assemblies with the same flow classification number is also okay).
        GTY519534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a QR Code
        *b Flow Classification Number
  3. INSTALL FUEL DELIVERY PIPE RH 
    1. Apply lubricant to the fuel injector assembly installation holes of the cylinder head sub-assembly.
    2. Temporarily install the fuel delivery pipe RH so that the stud bolts protrude enough to install the nuts.
      GTY462727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protruding enough to install nut
      NOTE:
      • If a fuel injector assembly is dropped or the tip of a fuel injector assembly is struck, replace it with a new one.
      • Check that there is no foreign matter or damage on the fuel injector assembly installation holes of the cylinder head sub-assembly.
      • When installing the fuel delivery pipe RH, push it in evenly without tilting it.
    3. Install the fuel delivery pipe RH by uniformly tightening the 3 bolts and 2 nuts in the order shown in the illustration.
      Fig 1: Fuel Delivery Pipe RH Tightening Sequence
      GTY496535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

    4. Tighten the 3 bolts and 2 nuts in the order shown in the illustration again.

      Torque: 29 N.m (296 kgf/cm, 21 ft.lbf) 

      NOTE:

      Make sure that there is no oil on the bolt threads and nut.

    5. Connect the 4 fuel injector assembly connectors.
  4. INSTALL FUEL DELIVERY PIPE LH 
    1. Apply lubricant to the fuel injector assembly installation holes of the cylinder head LH.
    2. Temporarily install the fuel delivery pipe LH so that the stud bolts protrude enough to install the nuts.
      GTY462727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protruding enough to install nut
      NOTE:
      • If a fuel injector assembly is dropped or the tip of a fuel injector assembly is struck, replace it with a new one.
      • Check that there is no foreign matter or damage on the fuel injector assembly installation holes of the cylinder head LH.
      • When installing the fuel delivery pipe LH, push it in evenly without tilting it.
    3. Install the fuel delivery pipe LH by uniformly tightening the 3 bolts and 2 nuts in the order shown in the illustration.
      Fig 2: Fuel Delivery Pipe LH Bolts And Nuts Tightening Sequence
      GTY509457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

    4. Tighten the 3 bolts and 2 nuts in the order shown in the illustration again.

      Torque: 29 N.m (296 kgf/cm, 21 ft.lbf) 

      NOTE:

      Make sure that there is no oil on the bolt threads and nut.

    5. Connect the 4 fuel injector assembly connectors.
  5. INSTALL CASE SEPARATOR 

    Refer to PROCEDURE - Step 2

  6. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY 
    1. Connect the No. 4 fuel pipe sub-assembly to the fuel delivery pipe LH and tighten the union nut by hand.
    2. Connect the No. 4 fuel pipe sub-assembly to the fuel delivery pipe RH and tighten the union nut by hand.
    3. Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe LH side of the No. 4 fuel pipe sub-assembly.

      Specified tightening torque 

      Torque: 35 N.m (357 kgf/cm, 26 ft.lbf) 

      GTY507350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Delivery Pipe LH
      *2 Fuel Delivery Pipe RH
      *3 Case Separator
      *a 17 mm Union Nut Wrench
      *b Torque Wrench Fulcrum Length
      *c Protector

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [09/2014 - 11/2017] , or refer to PRECAUTION [11/2017 - ]

      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N.m (306 kgf/cm, 22 ft.lbf)
    4. Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe RH side of the No. 4 fuel pipe sub-assembly.

      Specified tightening torque 

      Torque: 35 N.m (357 kgf/cm, 26 ft.lbf) 

      NOTE:

      After installing the No. 4 fuel pipe sub-assembly, check that the protector of the No. 4 fuel pipe sub-assembly contacts the case separator.

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [09/2014 - 11/2017] , or refer to PRECAUTION [11/2017 - ]

      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N.m (306 kgf/cm, 22 ft.lbf)
  7. INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY LH 
    1. Install the No. 2 engine cover sub-assembly LH.
  8. INSTALL FUEL PUMP WITH SEAL SUB-ASSEMBLY 

    Refer to INSTALLATION [09/2014 - ] 

  9. PERFORM INITIALIZATION 
    1. Perform "Inspection After Repair" after replacing a fuel injector assembly.

      Refer to INITIALIZATION [09/2014 - ]

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